LNG in Spotlight - Vahterus · 2020. 8. 29. · Vahterus Test Lab Was the Coldest Spot This Winter Valtteri Haavisto, Customer Service Director at Vahterus Vahterus is currently undertaking

LNG in Spotlight

The Future Is Bright on Land

and on Sea

Research & Development: Plate & Shell Heat Exchangers

in Cryogenic Applications

No.   1 2020

2

Vahterus Oy

Pruukintie 7

23600 Kalanti

Finland

+358 2 84 070

vahterus.com

Subsidiaries

Vahterus Americas LLC

Vahterus GMBH

Vahterus UK LTD

Vahterus Heat Exchangers

Zhangjiagang CO LTD

Publisher

Vahterus Oy

Editorial Team

Sara Karlsson

Hanna Kontu

Orders and feedback

sales@ vahterus.com

ON THE COVER

Front:

Testing Vahterus

heat exchangers

using liquid nitrogen at

a temperature of -180°C.

Back:

Details of nitrogen-

test equipment.

Photography:

Anton Sucksdorff

except pages 28–38

images courtesy of clients

11

3No.   1 2020

Contents

It Runs in the Family

8 How We Work

LNG Market Outlook – The Future is Bright

on Land and on Sea

The Path to Becoming LNG Experts

11 In Spotlight

Tobias Häggblom: Motivated by Teamwork

and Seeing the Bigger Picture

20 Meet Our Team

With Dekra Safety Comes First

22 Meet Our Partner

Vahterus Test Lab Was

the Coldest Spot This Winter

Vahterus FEM Simulations Rise

to the Cryogenic Challenge

6 Research & Development

Cabin John Ice Arena, USA

Cryostar, France

Enagas, Spain

Tri Tech Refrigeration, Australia

Panasonic Appliance Refrigeration System, China

Preston Phipps, Canada

28 Case Stories

Necessity Is the Mother of Invention, Crisis

Is the Driver of Change

26 Industry Insights

4

None of us could have guessed how radically the world

would have changed since we published the last issue of

our magazine. Most countries are in lockdown and all pub-

lic gatherings and events are banned. Travel is restricted

by special legislation. And all of this because of a sudden

and tragic virus pandemic that changed the way we live

and work in the space of just a few weeks.

Luckily, in the heat-transfer business, investments

continue to be made. Our customers are always striving

for ways to make energy savings and to find circular solu-

tions, and it’s our ambition to remain in partnership with

you, our valued clients, in researching this development

work. Together, we can improve our processes and dis-

cover sustainable solutions to tackle climate change and

ensure a safe environment for the next generations. We

thank you for your continued inquiries and orders. What’s

most positive is that our factories are operating at full ca-

pacity and there are no signs of the coronavirus in any of

our companies globally.

LNG opens doors

In this edition of Hot & Cold, we focus on heat-exchanger

solutions in LNG applications. Our customers are chang-

ing energy source from heavy fuel oil to Liquefied Natu-

ral Gas (LNG), which is becoming an increasingly popu-

lar fuel in marine and onshore applications and in power

generation.

The rich possibilities offered by LNG have encour-

aged us to undertake extensive R&D work to understand

the special features of heat transfer with cryogenic fluids.

For an engineer, it’s always exciting to see the extremes,

for example in temperatures, like using liquid nitrogen at

temperatures of -180°C to test our heat exchangers in an

Editorial

environment that’s equal to LNG vaporising conditions.

That’s pretty cold!

In these conditions, the materials, the welding qual-

ity, as well as heat-transfer efficiency of our exchangers

are rigorously tested. That has been our focus this spring.

On the following pages, you can read about a larger series

of cryogenic experiments in our Test Lab and about FEM

simulations that help us to continuously improve the con-

structions used in the cryogenic environment. We’ve also

successfully refined our processes. The development re-

search is done together with you, our customers, and the

work continues. I believe that the use of LNG will increase

significantly over the next decades, especially with large

engines. We at Vahterus are making it our business to be

part of this development work in the future.

Reasons to celebrate

Vahterus was founded on 5 September 1990 and we’re

approaching our 30th anniversary. Unfortunately, in the

circumstances it looks as if we’ll have to postpone our cel-

ebrations of this landmark event with you. It also seems

we won’t be gathering at exhibitions this autumn, because

most events have been cancelled.

However, we look forward to getting together with

you when the pandemic passes. In the meantime, we’ll do

our best to stay in touch on other platforms digitally.

I wish you health and continued success in your business!

Together we succeed!

Mauri Kontu

Founder and CEO

Development Continues Despite Difficult Times

5No.   1 2020

Founders Mauri and Sinikka Kontu photographed in the village of Vahterus.

6

Vahterus Test Lab Was the Coldest Spot This WinterValtteri Haavisto, Customer Service Director at Vahterus

Vahterus is currently undertaking an interesting series

of tests. Previously, we have focused on high tempera-

tures, phase-changing phenomena and fluid hydraulics.

This time, Vahterus test lab personnel are conducting a

larger series of cryogenic tests. Using liquid nitrogen at

temperatures of -180°C, it is possible to test our heat ex-

changers in an environment that is equal to or even more

challenging than normal Liquefied Natural Gas (LNG) va-

porising conditions.

We’ve undertaken extensive R&D work to further un-

derstand the special features related to cryogenic appli-

cations, and the aim of this large test series is to further

Research & Development

Vahterus is currently conducting a large series of tests to understand the special features related to cryogenic applications.

7No.   1 2020

Vahterus FEM Simulations Rise to the Cryogenic Challenge

Kalle Vähätalo, R&D Engineer at Vahterus

Low temperatures and widely varying temperature differ-

ences in cryogenic applications can cause high stresses

to the constructions. Practical testing of constructions

is often complicated and time consuming, which is why

modelling and simulation tools have become an important

part of the development process. During the last couple

of years, Vahterus has made many FEM (Finite Element

Method) simulations of constructions used in cryogenic

applications.

The FEM simulation process starts with the 3D mod-

elling of the studied construction. The geometry is then

divided into elements that constitute the calculation

mesh. Boundary conditions and loads describe the ex-

ternal forces and surroundings of the structure. The dif-

ferential equations representing the phenomena, such as

stresses and displacements in the structure, are numer-

ically solved. There are many methods for determining

structure lifetime, which generally use the highest stress-

es in the structure, as determined by FEM simulations.

When modelling and simulation tools are used, it is very

important to ensure that they are truly representative of

the problem studied. Vahterus employs its comprehen-

sive testing facilities to validate all models utilised in sim-

ulations.

Thermal stress is probably the most important factor

determining the lifetime of the LNG evaporator. The tem-

perature distribution inside the heat exchanger needs to

be defined precisely when thermal stresses are simulat-

ed. CFD (Computational Fluid Dynamics) simulations can

be used to determine the temperature distribution. From

2018–19, Vahterus collaborated with Tuomas Kyllönen of

Elomatic on his Master’s thesis, ‘Computational Fluid Dy-

namics Analysis of a Pressure Build-Up Unit of a Liquefied

Natural Gas Fuel System’, where he studied the tempera-

ture distribution inside the Vahterus heat exchanger.

Using FEM simulations has helped Vahterus to con-

tinuously improve the constructions used in the challeng-

ing cryogenic environment.

understand the special features of heat transfer with

cryogenic fluids. We’ve invented several unique solutions

that allow operations closer to freezing point, and extend

the unit’s lifespan in this demanding operating environ-

ment. As always, such development work requires both

theoretical understanding and practical testing in a re-

al-scale set-up.

The tests conducted so far strongly indicate that the

new products and new solutions will meet the targets

set. The most important finding has been the excellent

thermal cycling resistance of Vahterus Plate & Shell Heat

Exchanger.

Demand for cold recovery in LNG applications is push-

ing systems to provide increasingly low brine tempera-

tures. We investigated how to avoid brine freezing. One

target was to identify when and how the glycol starts to

freeze. Liquefied nitrogen was vaporised at about -180°C,

and 50% ethylene glycol was used as a heating medium.

We found that good heat-exchanger design makes it pos-

sible to use very low glycol outlet temperatures, avoiding

the risk of freezing. Even the cold side inlet temperatures

are less than the freezing point of glycol.

There are still plenty of tests to be done, but the start

has been strong.

8

Founded by Mauri and Sinikka Kontu, Vahterus is proud to be a family

business. The company also employs three members of the Ahola family.

Jukka Ahola has been with the company for the past two

decades. His daughters Anna Ahola and Elina Seikola

first came to Vahterus for summer jobs, Anna in 2006 and

Elina two years later.

It was an open Facility Manager’s position that

brought Jukka to Vahterus in 2000. He currently works as

a Maintenance Installer and team leader responsible for

the construction and maintenance of Vahterus’ produc-

tion equipment. With growth as a strategy, a lot of new

equipment is currently being built. Therefore, a significant

part of his work hours are spent in the office.

‘I work with the design team going through their draw-

ings’, Jukka says. ‘There’s a lot of paperwork involved in

purchasing materials and sourcing subcontractors. I keep

in touch with the companies we use for design and ma-

chining almost on a daily basis. The machines we build are

usually assembled by our skilful inhouse team, and I try to

be involved in the process as much as I can.’

Each family member expresses appreciation of the

others’ commitment, diligence and ability to solve prob-

lems. Jukka is happy about the success of his daughters

and their well-managed careers. One trait that clearly

unites the family is grit: the willingness to do the work re-

quired for achieving a goal.

‘My father is a doer, with his mind full of ideas’, Elina

says. ‘While others are still planning to do something, he’s

probably finished the job already. I can’t think of a task

that he hasn’t accomplished. Even if we present him with

an idea that seems challenging, he’ll find a way to over-

come the challenge and get things done.’

It Runs in the Family

How We Work

Vahterus Editorial Team

Elina works as a Project Manager in the Vahterus design

team. She graduated Master of Science in Technology in

2013 with a major in Industrial Economics and a minor in

Information Technology. As Project Manager, she is re-

sponsible for orders that require particular tailoring and

are therefore designated as projects, ensuring that the

customer receives the solution that meets their specific

requirements within the agreed timeframe.

‘A project manager is the link between the custom-

er and Vahterus design and production teams, keeping

everything tied together’, Elina says. ‘With tight sched-

ules, the ability to solve problems and proceed quickly is

essential. The challenge is that each project has its own

special requirements and there are no standard answers

to a question. However, by continuing to do the work, you

learn new things every day and develop a valuable skillset.’

Anna applied for a summer job at Vahterus in 2006

and following the first summer she came back year after

year, working as a Sales Coordinator. Having graduated

Bachelor of Business Administration in International Busi-

ness in 2013, she got a full-time job at Vahterus. A few

years ago, she started studying engineering in production

economics alongside work, and since April last year, she

has worked as a Sales Engineer in the Refrigeration team.

Anna enjoys the dynamic nature of her work and the

fact that every day is different. ‘Variation brings meaning

and allows you to challenge yourself’, she says.

In a fast-changing world, efficiency is improving and

sustainability is becoming increasingly important. This

naturally affects the needs of Vahterus’ customers.‘We

9No.   1 2020

have to develop ourselves constantly to be able to re-

spond to the changes in the market’, Anna says.

Just like her sister, Anna praises her father’s dili-

gence and grit. ‘I’ve learned from my father that in order

to achieve something, you have to be willing to work for it.

He’s also taught us about reliability: if someone is count-

ing on you to do something, make sure you do what was

agreed on. I try to stick to these principles’, she says.

Jukka, Anna and Elina work in different buildings,

which means they’re not constantly running into each

other at work. And yet there is a sense a security that

Jukka Ahola has

been with the

company for the

past two decades.

His daughters Anna

Ahola and Elina

Seikola first came

to Vahterus for

summer jobs, Anna

in 2006 and Elina

two years later.

comes from knowing that you have your family close by

and you have a family business as an employer.

Anna appreciates not only Vahterus’ values per se,

but also the way they are demonstrated in the culture

of the company: people are encouraged to take care of

themselves and everyone’s point of view matters.

‘Although Vahterus does business globally, the com-

pany’s roots and locality are always emphasised’, Elina

says. ‘Mauri [Kontu] always underlines the role of family

and health in overall well-being. These two can’t be ne-

glected if you wish to keep your work/life in balance.’

10

11No.   1 2020

Versatile and easy to transport, LNG is an increasingly popular fuel both

in marine and onshore applications. Besides energy, LNG is used as a raw

material in chemical processes, and its full potential is being unleashed

through heat transfer and cold recovery.

In January 1959, over 60 years ago, the world’s first LNG

ocean cargo was shipped from Lake Charles, Louisiana,

USA, to Canvey Island in England. The vessel herself,

a ‘methane pioneer’, was retrofitted from cargo ship to

32,000 barrel LNG tanker (the equivalent of a 5,000 CBM

LNG bunker vessel today). Its mission was to demonstrate

to the world that LNG could be transported safe and

sound – even over longer distances.

There are two key reasons why LNG is now being used

globally: firstly, when changed from gas to liquid at ambi-

ent pressure, LNG takes up 600 times less storage space.

Secondly, transportation is much easier, since the restric-

tions caused by pipeline infrastructure do not apply. The

diversity offered by LNG is the reason why it has become a

economically competitive alternative to traditional Natural

Gas. It has brought heavy competition to historical pipe-

line gas suppliers and other alternative fuels while lower-

ing the market prices. Technology investments are still

significantly higher than so-called commodity fuels such

as LFO, HFO and coal. However, times are changing rapid-

ly and awareness of the impact on human health and the

ecosystem of harmful GHG (greenhouse gas) emissions

is increasing. Natural Gas is one step in the right direc-

tion, since it creates approximately 20–25% less CO2 and

roughly 85% less nitrogen oxide emissions in combustion

LNG Market Outlook – The Future Is Bright on Land and on Sea

in comparison to diesel. When compared to coal, LNG of-

fers even greater benefits, with 40% less CO2 emissions

for equivalent power. At the same time, Natural Gas ex-

haust has literally zero particle matter and sulphur. LNG is

playing a growing role in the transition to a lower-carbon

energy system both onshore and offshore.

LNG is becoming an increasingly utilised fuel in the

marine markets. Marine vessels were originally powered

by wind and then steam. Next came the era of fuel oils

LFO/HFO. We are now at a new tipping point towards a

completely different means of power. Starting from this

year, shipowners globally will be required to fulfil the sul-

phur gap requirements of max 0.5% sulphur content in

fuel. In emission-controlled areas such as US coastal wa-

ters, the Baltic Sea and EU harbours, an even harsher limit

of 0.1% must be met. There are two ways to tackle this:

with a fuel that does not contain sulphur, or with a fuel

that has sulphur but with an exhaust-gas treatment.

For HFO, exhaust-gas treatment is required, which in-

volves Selective Catalytic Reduction (SCR) in combination

with either open- or closed-loop scrubber solutions. Both

have pros and cons. Open-loop solutions are banned by

many harbours, which lowers their future market predic-

tions. This makes the low-sulphur fuels – either Marine

Diesel (MGO) or LNG – the most attractive solutions for

In Spotlight

Frans Launonen, Key Account Manager at Vahterus

12No.   1 2020

most ship-owners. Marine Diesel comes at a premium

price, but only SCR is required in the process. With LNG,

not even SCR is needed. Often, the engines on vessels are

Dual Fuel (DF), capable of running either on LNG or marine

oils. Such engines are more expensive, but the owner ben-

efits from the flexibility of fuel sourcing. However, in terms

of storage and fuel-gas handling, there are downsides to

LNG. LNG/NG has more energy per kilogram than diesel/

MGO. This a benefit when you burn the gas, since you

need less fuel mass to produce the same power. However,

LNG requires close to half more storage space than die-

sel. Additionally, cryogenic solutions require more expen-

sive materials, such as stainless steel, and entail certain

safety issues. In the future, there will be vessels featuring

novel technologies such as hybrids and battery-driven

propulsion. Currently, battery-driven vessels are limited to

short routes with predictable operation, since charging in

harbours takes time. Hybrid vessels are likely to be used

on longer routes in the near future.

Safety has been a priority since the very first ocean

LNG cargo was transported in 1959. It is thoroughly ad-

dressed in the International Maritime Organization’s (IMO)

design guidelines ‘IGF code’ for gas-fuelled vessels, which

came into force in January 2017, along with Marine Clas-

sification Society guidelines. Even though the public see

LNG as hazardous, it only burns in certain limited condi-

tions. If there is roughly less than 4% Natural Gas in the

atmosphere, it is too lean to burn, and if there is more than

17%, it is too rich to burn, making it a safer option.

After the imposition of the 2020 sulphur-gap require-

ments, it is likely that for a short period MGO will take most

of the markets since it is so easy to use with no changes

to current vessels, but due to MGO’s premium price, LNG

is forecast to be the winner in the long run. For example,

DNV GL, a globally well-known classification society, is

forecasting LNG to become the leading fuel solution with-

in the next 20 years. This is a bold statement, considering

that there are currently fewer than 200 LNG-fuelled ves-

sels in operation in a global fleet of 50,000-plus vessels.

However, during this year there will be roughly 40% more

LNG-fuelled vessels on the market.

Vahterus has been developing the gas vaporisation

and heating technologies required. Our market share for

heat exchangers on LNG-fuelled vessels is over 50% and

our current high activity with our customers supports the

future growth expectations. Marine LNG solutions will be

utilised for all size classes and in different kinds of appli-

cations, from small LNG-powered tugs to the world’s larg-

est cruise vessels. In the future, efficiency and emission

reductions will be even higher. IMO has a target to cut

down GHG emissions by at least 50% by 2050 compared

to 2008. This is an ambitious but reachable target, despite

the fact that marine traffic will grow at the same time. LNG

will have a strong role here.

While there is much discussion of the use of LNG

in marine markets, it is mainly used in onshore markets.

Earth’s growing population and living standards will re-

quire more energy in the coming decades. The global

population grew by 700 million during the last decade.

That train is slowing down, but the United Nations is fore-

casting close to 1% annual population growth for the next

decade. Currently, the biggest buzz is around renewable

energy. There is a clear reason for this: renewables are be-

coming the cheapest option for consumers. This leads to

the biggest new challenge, which is the storing of energy

and handling the sudden peaks in demand when the sun

does not shine or there is no wind. Natural Gas and LNG

are favoured as an energy source in peak power genera-

tion because of their flexibility. Due to the fact that fewer

and fewer power producers want to buy baseload power

Thousands of new jobs

will be created in this field.

Universities are taking this

into consideration in their

courses and Vahterus has

been an active partner in this

development. We believe the

reasons for our high market

share are related to techno-

logical and application know-

how and we continue to work

closely with education to

create future jobs. Enhanced

cooperation with our partners

and customers, now and in the

future, is extremely important. If

you’re not ahead – you’re behind.

13No.   1 2020

generation and inflexible assets, large and inflexible units

are being shut down. CO2 intensive technologies are also

being kicked out of the portfolio one by one. During 2019

alone, over 300 TWh of coal generation was eliminated,

according to Shell LNG Outlook 2020. And this is just be-

ginning, since by 2040 it is expected that nearly 70 GW of

coal power generation will be cut (installed coal capacity

is now nearly 2,100 GW). In 2019, the largest amount of

global Natural Gas was consumed by power generation,

which was followed by the residential and commercial

sector, and then industry and transportation. By 2040,

the largest growth will be in the power generation market

in Asia.

Besides energy, LNG can be utilised in various ways

as a raw material in some chemical processes. In both on-

shore and offshore markets, the next revolution will be tap-

ping the full potential of LNG through heat transfer – the

‘cold energy’ recovered from the vaporisation process for

air conditioning, freezing/galley systems and on a larger

scale for district cooling networks. This will mean that net

This spring, Vahterus Test Lab has undertaken a larger series of cryogenic tests. Pictured here are LNG experts Frans Launonen (left)

and Lauri Bastman (right).

14

efficiency in current and future LNG-driven solutions can

be further increased by shutting down stand-by units or

those running on low load in the system, such as refriger-

ation units. Development will not stop at this point; it will

further concentrate on system levels, and the fruits of this

process optimisation will be seen not only in OPEX but also

as a CAPEX reduction due to more simplified processes.

LNG is not a one-size-fits-all solution. For years, the

tendency has been towards bigger LNG terminals, but

thanks to reductions in the cost of technology, LNG is

becoming available to small-scale consumers. Such LNG

facilities serving more modest demands usually have ca-

pacities of 30,000 cubic metres and lower. LNG is far from

a commodity fuel, but every day it comes a step closer.

Along with diversification to current Natural Gas markets,

LNG can enable rapid solutions for current and new mar-

kets in the form of Floating Storage Regasification Units

(FSRU). These floating vessels can be newbuild vessels

or old LNG carriers retrofitted to FSRUs, which are then

used to supply local consumers via Natural Gas pipelines.

The building times of FSRUs are much faster and permit

processes that are significantly easier if compared to

land-based LNG terminals. The building of an FSRU can

start in the shipyard without full permits. On a long-term

operation basis, onshore LNG terminal have slightly lower

usage costs, but with FSRU, you can sell the asset forward

on the markets if LNG demand drops in the user location.

This is a significant benefit that FSRU can offer over the

traditional land-based LNG terminals.

Lithuania is a good example. In 2014, the country

leased the FSRU called ‘Independence’ from Höegh LNG

under a ten-year contract. This was one step towards

more open Natural Gas markets in Europe and competi-

tion on gas pricing. Energy-wise, an FSRU can be com-

pared to a small nuclear plant, which can feed not only

flexible power generation but also baseload if required.

For example, ‘Independence’ could feed with her 170,000

CBM a 1,000 MW combined heat and power plant, on

stable load over one month on a 24/7 running basis. By

loading the FSRU between ~1-month intervals, this same

power could be generated constantly. Floating solutions

enable tailored solutions, especially for remote locations

such as islands, which are currently using traditional fu-

els like LFO, HFO or coal in their energy portfolio. In South

East Asia only, a 600% growth demand is expected by

2040 according to Shell, and floating solutions are surely

part of that expansion.

Even if LNG is considered the most environmentally

friendly fossil fuel, it is still, at the end of the day, a fos-

sil fuel. However, all current and future systems based

on Natural Gas can be switched to run on whatever is

the most environmentally friendly methane. The fact that

LNG-fuelled systems can be run with biogas and synthet-

ic gas makes them future-proofed. Many companies have

already done testing and even switched to biogas. This

is much more than a PR issue: it is a decision that makes

one company more sustainable than others, and will af-

fect customer buying decisions in the end.

The future of Natural Gas, and especially the LNG

industry, is bright. People in the industry are no longer

talking about the chicken and egg dilemma as they were

five years ago. The opportunities provided by LNG are

clearly recognised. Despite that, there is still room for

innovation and progress. Thousands of new jobs will be

created in this field in the future. Universities and schools

of applied sciences are gradually taking this into consid-

eration in their study selections. Vahterus has been in the

frontline of this development, and we want to guarantee

future workplaces together with study facilities. We be-

lieve the reasons for our high market share are related

to technological and application know-how. Our close

co-operation with our partners and customers now and

in the future is extremely important. If you’re not ahead –

you’re behind.

The future of natural gas,

and especially the LNG

industry, is bright. In both

onshore and offshore

markets, the next revolution

will be tapping the full

potential of LNG through

heat transfer – the cold

energy recovered from the

vaporisation process and

used for air conditioning,

freezing systems and on

a larger scale for district

cooling networks.

15No.   1 2020

Every expert was at one time a beginner; everyone starts

the journey from the same position of inexperience. This

is particularly true of those who are the forerunners of in-

dustry. There are no ready-made answers, there are no

well-established procedures, and there are no decades

of practical experience letting you know what works and

what doesn’t. That is, in the beginning.

For us at Vahterus, our journey with LNG properly be-

gan in 2005 with Boil-Off Gas heaters. Before that, we had

of course worked with Natural Gas in various applications

and temperatures, but now we were working close to the

liquid tanks and at cryogenic temperatures. The second

milestone came a few years later, when for the first time

ever, we started working with Liquefied Natural Gas. The

heat exchanger in question is still operating well to this

day, using cold methane liquid to condense LNG back into

a storage tank. The heat exchanger was not a very large

one, as they are these days, with only 60 kW of duty, or

about 450 kg/h of condensing LNG. But as a brave man

once said, sometimes small steps can be giant leaps.

It was certainly that way for us at Vahterus. We proved

in practice what we had known for a while: that the origi-

nal Vahterus Plate & Shell can be adapted and made ideal

for LNG applications. This was further proven just a short

while later, when we took another step and entered the

machinery spaces of LNG-powered vessels by supplying

LNG fuel vaporisers under strict Marine Classification So-

ciety guidelines.

With our willingness to collaborate on developing tailored

solutions, and the several benefits of our technology

compared to the more traditional solutions, we were the

obvious choice of manufacturer. There are numerous in-

herent benefits to our basic design, when compared with

competing technologies such as Shell & Tube. One of the

greatest of these is the small size. This minimises the use

of materials to bring down costs, and reduces the foot-

print – anyone who has visited the machine spaces on a

vessel will know that space is at a premium. Since the heat

exchanger tends to be one of the largest singular compo-

nents in an LNG skid, the small size of a PSHE allows for

massive space savings.

Unlike a Shell &Tube heat exchanger, a Vahterus LNG

vaporiser can vaporise and superheat the LNG inside the

same unit, in many cases completely removing the need

for a separate superheater. This brings further savings on

cost and space, and grants far greater flexibility to skid-

and piping-layout designers.

Doing something new is of course rarely plain sailing.

There are challenges when working with cryogenic LNG,

and we ourselves have met some of these over the years

as we constantly strive to innovate.

While the round plate is highly resistant to thermal

cycles, due to its small size a PSHE unit does not have

a large charge or reserve of hot media, such as glycol-

water, inside it. Consequently, a poorly designed Plate

& Shell unit built without taking the system’s special

Vahterus’ LNG journey began in 2005. Through extensive R&D work

and with over 300 heat exchangers delivered to cryogenic LNG

applications, we’re now leaders in the field.

The Path to Becoming LNG Experts

In Spotlight

Lauri Bastman, Sales Engineer at Vahterus

16No.   1 2020

17No.   1 2020

Vahterus LNG vaporiser can

vaporise and superheat the LNG

inside the same unit, in many cases

completely removing the need for a

separate superheater. This brings

further savings on cost and space,

and grants far greater flexibility to

skid and piping-layout designers.

18

An exciting new

trend in LNG-

related applications

is the growing

number of cold

recovery systems.

The idea behind

cold recovery is

simple: energy

has already been

applied to liquefy

the LNG and store

it in cryogenic

conditions.

19No.   1 2020

Our custom-built LNG heat exchangers implement several solutions to

ensure the best possible functionality in all operating conditions. Our

development work has constantly broken new ground and we have

several patents pending for cryogenic heat transfer.

requirements into consideration can lead to freezing is-

sues and non-functionality of the exchanger. With simula-

tions and data from the field, we have identified the caus-

es and mechanisms behind such potential dangers in our

exchangers, and our tailor-made LNG heat exchangers

implement several solutions to ensure the best possible

functionality in all operating conditions. Our development

work has constantly broken new ground and we have sev-

eral patents pending for cryogenic heat exchange.

But the challenges go even deeper – to the very foun-

dations of heat transfer. As the original inventors of the

entire Plate & Shell technology, during the foundation of

our company 30 years ago there were no ready-made

methods of directly calculating heat-transfer coefficients

or other necessary information for even the simplest ap-

plications. We adapted the well-established principles

of general heat transfer and equations made for oth-

er technologies to our own needs based on testing and

real- world experience. When we introduced LNG appli-

ca tions as possibilities for Plate & Shell, we had to adapt

those equations again based on new data. Thanks to

the efforts of our extensive R&D programme and years

of data from operational heat exchangers, we have now

developed our very own fine-tuned custom-built ther-

mal design programme for LNG applications, allowing us

to model their thermal behaviour, freezing potential and

much more.

Yet work remains to be done. We fully intend to re-

main at the tip of the spear, leading the technology and

market in onshore and marine LNG heat exchangers. This

requires further development of brand-new ideas, refin-

ing, testing and improving technology, in order to provide

the best possible solution to our customers. Our ongoing

R&D programme plays a critical role in this, and we con-

tinue to invest heavily in it. This spring, we are launching

large-scale active testing in our own laboratory for LNG

exchangers, with a dedicated customised testing rig for

even more extreme conditions and greater capacities,

using cryogenic liquid nitrogen to provide us with more

data to supplement our small-scale liquefied nitrogen

tests. This data will be further refined and combined with

the use of computer simulations to ensure our know-how

remains the best in the world, and we are always on the

lookout for new possibilities to apply this knowledge in

environmentally conscious ways.

An exciting new trend in LNG-related applications is

the growing number of Cold Recovery systems. The idea

behind Cold Recovery is simple: energy has already been

applied to liquefy the LNG and store it in cryogenic con-

ditions. This LNG has then been transported elsewhere.

If the LNG is simply vaporised and heated for use, its lo-

cal cooling capacity is wasted. So instead, why not hook

up HVAC or refrigerator systems to the LNG vaporisation

process? This way, there is no need to expend further en-

ergy on creating artificial cold. With our 30 years of experi-

ence in the refrigeration industry and natural refrigerants

like ammonia and CO2, we have a good understanding of

both sides of the Cold Recovery process. This enables us

to pool our assets and knowledge on related application

development.

The road we have travelled has brought us to the

point where we can truly call ourselves experts. We have

done countless simulations and tests, have close to 20

years of continuous experience in the field, have delivered

over 300 heat exchangers to cryogenic LNG applications,

and have been involved in more than half of the current

LNG-powered marine vessels on the planet. With this list

of merits, we can proudly say we are the industry lead-

ers. Our Plate & Shell technology is not some exotic new-

comer on the market, but a well-proven industry standard

solution on land and on sea.

This path has only been possible with dedication,

hard work and collaboration with our partners and cus-

tomers, and we look forward to continuing on that road by

developing tailor-made solutions for our customers and

meeting future challenges.

20

In addition to short-term goals, Tobias Häggblom sees a bigger picture in his work: ‘Our product is meant to last for decades rather

than only focusing on the next quarter.’

21No.   1 2020

Tobias Häggblom works as a Business Manager responsible for our

Energy team. In his daily work, he enjoys rising to a challenge instead of

giving up and finds meaning in working for a company with sound values.

Motivated by Teamwork and Seeing the Bigger Picture

Meet Our Team

What’s your role at Vahterus?

I started in 2006 as a Sales Engineer, then became a Key

Account Manager in 2008 and a Sales Manager in 2012.

Since 2014, I’ve led our Energy team.

What do you like best about your job?

I like the mixture of technical challenges, sales and man-

agement. We have a great team of people.

How is your typical day at work?

The days vary greatly. One day can be an office day, work-

ing with heat-transfer solutions. The next day I might be

travelling to the other side of the globe and working with

our clients to find the best solutions for them.

When do you feel you’ve succeeded in your work?

In a sales environment, hitting the budget is of course

your main target. It’s always great when the whole team

can celebrate work well done. It’s also rewarding when

you’re able find good solutions to challenges.

What kind of situations bring out your best qualities?

I rarely give up. I like to take on a challenge, and I like the

reward when it’s overcome.

What do you consider Vahterus’ most important value?

Sustainability. It’s embedded in the business and the

product, which is designed to last for decades.

If you weren’t at Vahterus, what would you be doing?

Engineering has always been my passion and choosing

what to study was never difficult. I graduated Master of

Science in Technology from Åbo Academi University. If my

job wasn’t related to engineering, I’d probably be working

with something sales-related.

How do you spend your time outside work?

I have three kids aged eight to ten, so coming up with ways

to pass the time is never an issue. If there is extra time, I like

to do things with my hands, like DIY projects, or golf or fish-

ing. I used to do cross-country skiing but had to change to

mountain-biking due to the poor winter conditions.

In the midst of everyday life, what delights you?

Spending time with my family. It gives a great balance

when you come home after a stressful day at work.

What have you found positive about the experience of

the coronavirus crisis?

I’m impressed by how well remote teaching works now

that the Finnish schools are closed. My wife is a teacher,

and she’s currently doing several video conferences a day.

Applications such as WhatsApp and Teams are making it

all possible. I’ve also been really impressed by how well the

kids work independently with their school tasks.

Which new skill would you like to learn?

A new language – Spanish, for example. I’ve read the ba-

sics, but it would be nice to speak it fluently.

Which of your co-workers would you like to praise?

I have to mention the entire Energy team. We have a real-

ly good mixture of people working very well together to-

wards a common goal.

22

Testing company Dekra ensures reliably and impartially that

Vahterus heat exchangers meet all safety requirements.

Dekra is an independent testing company with official au-

thorisation. The company is focused on technical inspec-

tions, conformity assessments, testing and certifications

in different areas of industry. The purpose of its opera-

tions is to reliably and impartially ensure that basic safety

requirements are met.

The design and manufacture of pressure equipment

is regulated by legislation and, in addition to EU directives

and standards, is subject to national regulations. Vahterus

heat exchangers are welded pressure vessels that by law

must be subjected to non-destructive material testing.

Dekra is Finland’s leading expert in non-destructive test-

ing and Vahterus’ chosen partner in this work.

Dekra Industrial Oy began its operations in Finland in

1974 under the name Polartest Oy. Today, the company is

owned by Dekra SE, the third largest inspection and test-

ing company in the world, with headquarters in Stuttgart,

Germany. Vahterus began working with Polartest 25 years

ago. With Dekra’s acquisition, Polartest became part of

Dekra, and the collaboration with Vahterus continued.

‘For Vahterus, cooperation with Dekra is important’,

says Matti Kontu, Production Director at Vahterus, ‘be-

cause its work is necessary for showing that the pressure

vessel and its welds meet all the requirements’. The quali-

ty of metal structures can be measured by both breaking

the material (DT, destructive testing) and without break-

ing the material (NDT, non-destructive testing). NDT looks

for surface or hidden deficiencies in the material that may

lead to failures or malfunctions. Research methods in-

clude surface and volumetric inspections.

With Dekra Safety Comes First

´At Vahterus, virtually all basic testing methods are used,

says Jarmo Aitta, Regional Manager at Dekra. ‘Applied

surface inspection methods include visual testing, mag-

netic-particle testing and liquid-penetrant testing. Fluo-

rescent methods have also been used, but less frequent-

ly. In volumetric inspection, the most used methods are

radiographic and ultrasound testing. Lately, there’s been

an increase in the use of digital radiography and phased

array ultrasound testing.’

NDT is standardised, and at Vahterus, testing is per-

formed by Dekra in two shifts daily. Four people work per

shift and practically every product on the production line

undergoes some non-destructive testing. The radiation

space is lined with lead, which enables the use of radi-

ography during a normal shift. All testing is performed at

the Vahterus premises, but the testing equipment is the

property of Dekra.

The test regulations and scope come from pressure

vessel legislation, so that’s not really in our hands’, says

Kontu. ‘However, the more consistent the quality of Vahter-

us production is, the fewer errors are found in the tests,

which then minimises the need for corrective work. The

error rate is constantly monitored at the level of the entire

production as well as the personal level of each welder.’

Aitta reports that the inspection methods have devel-

oped greatly over the years, and at Vahterus it has always

been possible to introduce the most advanced methods

at an early stage. Besides testing, the heat exchangers

and their materials have evolved, which has led to new

challenges in different inspection methods.

Vahterus Editorial Team

Meet Our Partner

23No.   1 2020

NDT is standardised, and at Vahterus, testing is performed by Dekra in two shifts daily.

‘I personally think that Vahterus has invested in quality and

strived to develop both welding methods and processes

that alleviate testing. Various inspection-related aids have

been created or even purchased for our assistance. Dekra

has also been involved in testing new products made us-

ing new welding methods and production equipment al-

ready in the pilot phase. This has further increased the

inspectors’ motivation and expertise’, says Aitta.

Dekra is also one of Vahterus’ partners in des-

tructive testing, as well as in the supervision of

welding- method tests and proficiency tests. Destruc-

tive testing is performed on welds and base materials.

One of the key areas in the collaboration between

Dekra and Vahterus has been the development of work-

ing methods and information systems. About five years

ago, a new documentation management system was

introduced, and for the past two years, all of Dekra’s in-

spection reports have been completed electronically. The

reports are automatically transferred to Vahterus’ system

within one hour of signing. All reports are also available to

the inspectors who visit Vahterus, which makes it easier

to keep track of the inspections and write new reports.

24No.   1 2020

Dekra’s Regional Manager Jarmo Aitta thanks Vahterus for its proactivity. ‘I personally think that Vahterus has invested in quality and

strived to develop both welding methods and processes that alleviate testing. Dekra has also been involved in testing new products

made using new welding methods and production equipment already in the pilot phase. This has further increased the inspectors’

motivation and expertise’, he says.

25No.   1 2020

At Vahterus, virtually all non-destructive testing methods are used. Applied surface inspection methods include visual testing,

magnetic-particle testing and liquid-penetrant testing. Fluorescent methods have also been used, but less frequently. In volumetric

inspection, the most used methods are radiographic and ultrasound testing. Lately, there’s been an increase in the use of digital

radiography and phased array ultrasound testing.

26

Necessity Is the Mother of Invention, Crisis Is the Driver of Change

Industry Insights

The global challenges posed by the climate crisis, Covid-19 and

the drop in oil prices are spurring innovation. Pharmaceutical

companies are striving to produce vaccines and new medicines, while

natural refrigerants and cold recovery through LNG are becoming

increasingly energy-efficient solutions.

As the world fights the coronavirus pandemic, the outlook

for the process and chemical industry has significantly

changed.

Pharmaceutical producers are working hard to de-

velop a vaccine against the virus, as well as increasing

the production of the various medicines needed during

these critical times. Looking at the list of heat exchang-

er units leaving our factory in Kalanti over the past few

weeks, it is notable that the demand for reactor tempera-

ture control heat exchangers and solvent condensers

used in pharmaceutical production facilities has radically

increased.

Lockdown and social distancing have led to innova-

tion and rethinking of the way we work. Operating from

home without personal contact with colleagues and

cus tomers has forced us to use new technologies and al-

ternative means of communication.

The outlook for Vahterus’ business in the chemi-

cal sector during 2020 remains positive. We now have

the new PSHE 12 model fully tested and ready, and it is

well-suited to many applications in the industry.

One of Vahterus’ long-term customers in the chem-

ical industry, German giant BASF, has launched a cam-

paign called ‘Helping Hands’: it is donating to healthcare

facilities over 100 million protective masks and 1 million

litres of disinfectants in Germany alone. BASF has also

started the production of hand sanitisers in other coun-

tries in order to donate them to fight the virus. This is just

one inspiring example of a company giving back to those

in need at a time of crisis.

Chemical and ProcessMarko Rantala, Sales Director at Vahterus

27No.   1 2020

If I’d written this article before the end of last year, its tone

would have been completely different. Although 2019 was

far from the best, it was a solid year in the energy busi-

ness, with a good level of investment.

The drop in the price of oil brought turmoil at the

beginning of this year, as more and more news about

the coronavirus outbreak started spreading from Chi-

na. However, this wasn’t the only reason why oil prices

dropped so significantly. The price war between Russia

and Saudi Arabia dragged out the decision to cut pro-

duction. Thus overproduction and full storage resulted

in a negative oil price for a short time. The price is now

slowly climbing back.

Luckily, the price of oil isn’t the only driving factor

for energy investments. Environmental regulations are

The biennial main event of the refrigeration was sched-

uled to take place in Nuremberg this fall.

Writing this statement in June, there’s a lot of uncer-

tainty in the air. China Refrigeration Expo 2020 in Wuhan

was postponed, the 2020 IIAR Annual Conference in Or-

lando was canceled and we’ve just received a notice of

cancellation of Chillventa 2020, launching a virtual event

this October. The coronavirus pandemic has dominated

front pages this spring.

Additionally, this past winter has been the warmest

recorded in Europe, scientists have announced, with

snow having to be imported for winter sporting events.

In Helsinki, Finland, the average temperature for Jan-

uary and February was more than 6°C higher than the

1981–2010 average. Meanwhile in the Southern Hemi-

strongly pushing investments towards gas and LNG. This

spring, Vahterus R&D team has been working on an inter-

esting series of tests related to cryogenic applications.

As the use of LNG increases, so do the possibilities to re-

cover cold from LNG in different applications. Recovering

cold means getting close to the freezing limits of brine. It’s

therefore extremely important to understand how low it’s

possible to cool brine.

Shipping continues to get greener. An increasing

number of ships, both new and converted, are running

on low-emission fuels. You can read about the possibil-

ities offered by Vahterus Plate & Shell Heat Exchanger

solutions in this magazine. There’s plenty of potential for

growth and innovation in this industry, even with lower

oil prices.

sphere, record-breaking temperatures and months of

severe drought have fuelled a series of massive bush-

fires across Australia.

There’s no denying it, the climate is changing. And we

must look to the future. Natural refrigerants, energy re-

covery and heat pumps are one of the key solutions to

building a clean and safe environment for the next gen-

erations.

Here’s hoping we’re able to get together soon and

seize the opportunity to discuss these significant chal-

lenges together. We’ve already been very effective in

implementing the decreased use of refrigerants with

ozone-depleting issues to safeguard our environment.

Together, we can develop further safe and sustainable

solutions to tackle the climate crisis.

Energy

Refrigeration

Tobias Häggblom, Business Manager at Vahterus

Heikki Oksanen, Business Manager at Vahterus

28

In September 2019, Vahterus supplied PSHE 8/6HH-

460/1/1 unit, a critical-charge combined ice-rink chiller,

to Ultimate Fabrication Inc, located in Edmonton, Alber-

ta, Canada. The unit was commissioned in October 2019

and it has been running as a part of new cooling system

for Cabin John Ice Arena in Rockville, Maryland, USA. The

Vahterus PSHE Combined Chiller (a chiller with an inte-

grated separator in one shell) was a key component in the

upgrade project of the NHL and studio-size ice rinks in the

Cabin John Ice Arena.

This single heat exchanger solution was designed

with two different-sized (separate) plate packs, us-

ing one common NH3 chamber. The larger plate pack

was designated to cool the NHL-sized arena, with the

smaller plate pack providing cooling for studio-size

rink. Each plate pack chilled different flow rates of

ethylene glycol from -7.5°C (18.5°F) to -9C (15°F), with

the NH3 evaporating at -12 °C (10°F). This novel instal-

lation allows the rinks to run either independently or

consecutively, providing a compact and cost-effective

solution for the end customer.

The chief designer of the cooling system was Art

Sutherland of Accent Refrigeration, a natural refrigerant

advocate, who has been working together with Vahterus

for over a decade.

‘We designed the system to optimise both electrical

efficiency and thermal efficiency’, said Sutherland, ‘as

well as totally eliminating thousands of pounds of high

GWP and ozone-depleting refrigerant. By removing all the

equipment from the former indoor machine room, more

valuable building space would become available.’  

The system that was removed was a direct refriger-

ation system with over 3,630 kg (8,000 lbs) of R-22 inside

the public space. With the new Vahterus low-charge sys-

tem, the arena facility now has less than 225 kg (500 lbs)

of ammonia in a self-contained machine room outside of

the public space.

Sutherland continued ‘The new system, utilising am-

monia, as well as highly efficient Mycom M compressors

and a very close-approach Vahterus chiller, is appreciably

more efficient than the previous direct refrigeration sys-

tem.’ The new system has two 125 horsepower compres-

sors compared to the old system with two 150 horsepow-

er compressors. Additionally, the new system operates on

one compressor with run times approximately 20% less

than the old system.

This new cooling system was designed with an envi-

ronmental gain in mind, not only by switching from R-22

to ammonia, but also by maximising electrical and ther-

mal efficiency. Key to achieving this was the fact that the

entire design concept embraced technological advances.

Change can often bring uncertainty and fear, but as can

be seen in this case, with the correct design and the right

components, the operational and environmental gains are

considerable.

One Vahterus Combined Chiller Cools Two Ice Rinks in Maryland

Jonathan Pascoe, President at Vahterus Americas and Mikko Tuomainen, Key Account Manager at Vahterus

Case Stories

The building package leaving Ultimate Fabrication. The 15 m

(150 ft) long trailer weighed 50 tons (110,000 lbs).

29No.   1 2020

Vahterus Combined

Chiller inside the

arena package. The

new cooling system

was designed with

an environmental

gain in mind, not

only by switching

from R-22 to

ammonia, but also

by maximising

electrical and

thermal efficiency.

30

Founded in 1972, Cryostar specialises in designing and

manufacturing cryogenic equipment. The company offers

turbomachines, gas heaters and vaporisers, pumps, tur-

bines as well as compressors for industrial gas, energy

and hydrocarbon applications. In the twenty-first century,

the company has extended its range to process plants in

the fields of natural gas and clean energy.

Cryostar employs 500 people at its headquarters in

Hesingue, France, in the centre of the three-border region

constituting France, Germany and Switzerland.

90% of the company’s production is exported. During

almost five decades in operation, Cryostar has developed

an international network through distributors and agents

in Italy, Spain, Japan, Korea, India, South America, along-

side its own branches that employ 100 people in the UK,

Singapore, China, Brazil and the US.

Cryostar has been involved in LNG applications for

several decades. In the year 2000, the company was one

of the pioneers developing truck-fuelling stations. Two

kinds of truck technologies co-exist and they require dif-

ferent pressures and temperatures in the reservoir. Initial-

ly, the standard fuelling stations included a device to heat

and saturate LNG in the storage tank.

As a technological leader, Cryostar saw an opportu-

nity to change this. The company decided to develop an

‘on the fly’ saturation system that would warm the LNG on

demand when fuelling the truck.

Compared to the old technology, the two main advan-

tages of this solution are the ability to:

– deliver low temperature LNG to trucks that support

it, and therefore increase their autonomy and avoid any

possible vent of their storage tank

– keep cold LNG in the storage tank and reduce or

avoid the need to cool it down, which requires plenty of

energy. This creates significant energy saving, leading to

an optimised environmental aspect.

In order to perform quick cooling down and avoid heat

ingress into the system, Cryostar was looking for a com-

pact and high-efficiency cryogenic heat exchanger. At

Cryostar, selecting suppliers is a key activity, where pur-

chasing, QHSE and engineering teams work together on

an evaluation matrix. In this case, Vahterus was selected

as a partner mainly for its product’s technology, design

and calculation capacity.

Cryostar was able to adjust its process so that it re-

sulted in optimised size and heating capacity of the heat

exchanger. An engineering expert from Cryostar partici-

pated in a class at Vahterus premises in Finland, and was

then able to make all calculations on his own. The two

companies exchanged 3D models, which were compati-

ble, and by the time the first heat exchanger was shipped,

no support from Vahterus was needed for installation.

Today, Cryostar is convinced it made the right choice

when selecting Vahterus as a partner. The company has

been able to deliver saturation system units to Canada,

Cryostar’s Saturation System Transforms Truck-Fuelling Stations

Vahterus Editorial Team

Case Stories

Cryostar was looking for a

compact and high-efficiency

cryogenic heat exchanger. Today,

the company is convinced it made

the right choice when selecting

Vahterus as a partner. The first

Vahterus heat exchanger was

installed in 2013 and is still in

operation, alongside roughly

60 further Vahterus units in

Cryostar’s systems.

31No.   1 2020

Australia and Europe and more recently has qualified the

design for Shell.

Because of the challenging operating conditions, the

Vahterus heat exchanger is a good solution for Cryostar’s

system. Besides being compact in size, its fully welded

structure eliminates the need for a gasket that could eas-

ily break in such a low operating temperature.

The first Vahterus heat exchanger was installed in

2013 and is still in operation, alongside roughly 60 further

Vahterus units in Cryostar’s systems today. This kind of

long-term cooperation is extremely valuable for Vahter-

us, deepening the understanding of how the market, and

possible applications for heat exchangers, are evolving.

Experts at Cryostar consider LNG the perfect transi-

tion fuel between oil and the future mix of greener sourc-

es of energy. When used as a fuel, LNG or CNG reduces

CO2 emissions; it drastically decreases particle emissions

and is less noisy than diesel-driven engines. Moreover, it

allows an easy transition to bio-LNG, a completely CO2

neutral fuel.

LNG can be used for replacing LPG and oil in industri-

al applications, diesel for road trucks, gasoline and diesel

for personal cars, heavy fuel oil or other fuels for ships,

as well as any other energy source for power generation.

In the future, more and more of our built environment

will be powered by renewable sources of energy such as

solar, wind, hydrogen, biofuels and biogas. However, there

are still major issues to be solved – for example, energy

storing and learning to use different sources of renewable

energies for different applications.

Until the new technologies have become established,

LNG helps to fill the gap by continuing to supply different

applications while slowly reducing the footprint on the en-

vironment and enabling an easy transition to biogas.

Vahterus Plate & Shell

Heat Exchanger integrated

into Cryostar’s saturation

system. The first Vahterus

unit was installed in 2013.

32

Enagas is a company with 50 years’ experience of working

with the gas supply, both in Spain and globally. It owns and

operates the Spanish national gas grid, as well as having a

presence in other EU-countries and in Latin America.

With a team of three to five people, e4efficiency is a

small department within the giant Enagas corporation. A

kind of R&D hub, it tests and develops projects that can

be scaled up later. Its projects in progress deal with the

production, transport and commercialisation of the cold

energy inherent in LNG. While minimising carbon foot-

prints, such cold-harvesting projects also lead to eco-

nomic savings and bring new businesses to under-used

port areas, where the LNG is processed.

Vahterus’ first communications with Enagas in ge-

neral and with e4efficiency in particular began back in

2012. ‘We received very good references about Vahterus

products from people in our Bilbao regasification plant,

where they have one heat exchanger operating with excel-

lent results’, says Ana M. Azuela Gómez, Project Engineer

at e4efficiency. ’Our refrigeration specialist also recom-

mended Vahterus Plate & Shell Heat Exchangers because

of their cost, size and operation. We received recommen-

dations from both the regasification and industrial world,

so we had no doubt when choosing a heat exchanger.’

Vahterus’ willingness to innovate and experiment was

also an important factor: ‘There’s a very good relationship

between e4efficiency and Vahterus, not only on a com-

mercial level, but they also help us continuously in new

studies and proposals’, says Azuela Gómez. ‘They’re open

to researching new exchanges and processes, which is

greatly appreciated by an innovative start-up like e4effi-

ciency. We’d also like to highlight the fast response that

we receive from Vahterus in all technical aspects.’

From the very beginning, the focus of discussions was

on the applications related to the use of LNG. One of the

ideas developed between Vahterus and e4efficiency was

to utilise cold energy from the vaporisation of LNG. With

conventional technologies, this was dumped into the sea,

but e4efficiency saw a potential for its use as a source of

cheap energy for logistics centres surrounding harbours.

As a result of collaborative thinking, Vahterus and

Enagas developed a ‘cold box’ system, which consists of

an exchange system and pumps. The pumps propel the

refrigerant towards the client’s facilities in a closed loop,

at the temperature they require.

In this system, high-pressure LNG is passed through

an exchange system of two Vahterus heat exchangers,

one with LNG/intermediate fluid and the other with in-

termediate fluid/refrigerant fluid. The intermediate fluid

circulates between the exchangers through a process

LNGenius: Clever Cold Energy Recovery in Spain’s Ports

Grigory Konkov, Key Account Manager at Vahterus

Case Stories

One of the ideas developed

between Vahterus and

e4efficiency was to utilise

cold energy from the

vaporisation of LNG. With

conventional technologies,

this was dumped into the

sea, but e4efficiency saw

a potential for its use as a

source of cheap energy for

logistics centres surrounding

harbours. Savings on elect-

ricity will attract companies

closer to the harbour.

33No.   1 2020

of thermosiphon, and through the difference in density

between the liquid phase and the gas phase, without the

need for pumping. The temperature of both the interme-

diate fluid and the refrigerant may vary, depending on the

needs of the customer. The cold energy of the LNG is

recuperated, and can be made available to clients who

require it, from refrigerated warehouses and ice facto-

ries, to industrial, pharmaceutical customers, data cen-

tres, etc. In theory, it will become a trouble-free solution

with no risk of freezing the CO2 or the Temper (the refrig-

erant), since the LNG does not come into direct contact

with them, but transfers cold energy through the inter-

mediate fluid.

This idea was first tested with a 35 kW skid from 2018

to 2020, with positive results. The second prototype, with

a capacity scaled up to 370 kW, is getting ready for start-

up in the coming months in Huelva, Spain. Azuela Gómez

remarked: ‘We’ve had a very good experience with the two

Vahterus exchangers that we have in the LNG cold-har-

vesting prototype. Both the LNG / Ethane and the Eth-

ane / Temper systems work perfectly, with an adequate

temperature transmission speed and without requiring a

cooling curve that’s too slow. Furthermore, during the pro-

totype start-up, two Vahterus technicians were present,

which was very helpful for us.’

Having looked at the results of the two test skids, Ena-

gas has begun two ‘full-scale projects this year, amount-

ing to 14MW of cold-energy recovered using this tech-

nology: project ‘Barcelona’ and project ‘Huelva’. These are

harbour locations in Spain, where Enagas receives LNG

from tankers and will be able to develop the surrounding

area by attracting companies to move closer to the har-

bour. In those projects, it is expected that end clients will

make 25–40% savings compared to the use of electricity,

when moving their facilities closer to the port. And this is

just a beginning: with the demand for cold energy increas-

ing around the globe due to global warming, there will be

plenty more projects to come.

According to Azuela Gómez, e4efficiency will con-

tinue to work with Vahterus: ‘Due to the good results ob-

tained so far, we hope to keep working with Vahterus Plate

& Shell Heat Exchangers, even improving on these great

results and implementing this technology in new process-

es with LNG as the protagonist.’

Vahterus and Enagas developed a ‘cold box’ system, which consists of an exchange system and pumps. The

pumps propel the refrigerant towards the client’s facilities in a closed loop, at the temperature they require.

34

Established in 1994, Tri Tech Refrigeration Australia is

one of the leading industrial refrigeration service and con-

tracting providers in Australia, with a particular focus on

the natural refrigerants ammonia and CO2.

Zammit Ham & Bacon Curers is a family owned and

operated company whose humble origins date back to

1954, when Francis Zammit, a butcher by trade, migrated

from Malta to Australia and with the help of his sons, be-

gan producing Maltese sausages for the local community.

In 1958, the Zammit family expanded its business and be-

gan producing hams – the products for which the compa-

ny is now renowned. Zammit Ham & Bacon Curers handle

the production of small goods through all its stages and

create a unique product by utilising the latest technologi-

cal efficiencies to control and monitor the curing, cooking

and packaging of the products at their factory premises in

Pendle Hill, Sydney.

The ammonia refrigeration plant at the Zammit’s Pen-

dle Hill facility was designed, installed and commissioned

by Tri Tech Refrigeration Australia in 2014. In 2018, two

new production areas for small goods slicing, packaging

and packing were built in a location far from the existing

chilled glycol infrastructure. Therefore, a remote glycol

chiller and pump skid was needed that could be connect-

ed to the existing high-ammonia, high-pressure liquid and

dry-suction mains and also fitted to new localised glycol

mains services in the two new production areas. Glycol,

rather than ammonia is commonly used in production ar-

eas occupied by people for safety reasons.

The proposed glycol chiller and pump skid needed

to use ammonia, the plant’s primary refrigerant, to cool

a 30% propylene glycol solution, which in turn was used

as a secondary refrigerant to provide refrigeration for two

new production areas operating at between 8°C (46.4°F)

and 12°C (53.6°F).

A 250kW (71 ton) heat exchanger was required

that could cool incoming 30% Propylene Glycol at 1.5°C

(34.7°F) to -3.5°C (25.7°F) using ammonia at a saturated

evaporating temperature of -9°C (15.8°F).

After evaluation of various heat exchanger types and

configurations, Tri Tech Refrigeration Australia opted for

a Vahterus PSHE 5/4HH Combined Plate & Shell Heat Ex-

changer for the following reasons:

– Compact size: relative to ‘conventional’ flooded

plate heat exchangers, two of which were of similar ca-

pacity and installed elsewhere in the plant in 2014, the

Vahterus unit selected allowed for a skid with a smaller

footprint.

– Cost reduction: the Vahterus unit selected allowed

for an overall reduction in skid cost given that there was

no need for an external surge drum and interconnecting

pipes and valve. Insulation was also simpler, allowing for a

further cost reduction.

– Improved safety: the fully welded design reduced

potential for leakage compared to semi-welded/gasket-

ted or brazed plate heat exchanger units.

The skid configuration features:

– Level control: Danfoss SV4 pilot float and PMFL

80-3 main valve, allowing for faster commissioning time

and fewer PLC controls.

– High level protection: Hansen HLLe float with

high-level cut-off on EVM NC pilot fitted in SI port of PMFL

80-3 and a secondary ammonia suction trap downstream

in the main plant (desirable but not essential).

– Pressure protection: dual Hansen relief valves set at

1800kPa (261 PSI) on the shell side and glycol circuit fitted

with 600kPa (87PSI) pressure relief.

– Ammonia controls: suction line fitted with Danfoss

ICS 80-3. SI & SII ports fitted with EVM and CVP, allowing

on/off control at -9°C SST (201kPa(g)) (15.8°F (29.15PSI)).

P port fitted with CVP set to relieve at 0°C SST (328kPa(g))

[32°F (47.57PSI)).

Safe Production Expansion with Ammonia Glycol Chiller and Pumping Skid

Mack Hajjar, Projects Engineer at Tri Tech Refrigeration Australia

Case Stories

35No.   1 2020

A 250 KW pumped

glycol skid with

Vahterus Combined

PSHE in service at

Zammit factory in

Sydney, Australia.

– Glycol controls: glycol set at full flow with minimum

flow bypass without using pump VSD. Glycol tempera-

tures controlled by opening and closing the suction EVM

(and therefore opening/closing) main suction valves to

achieve glycol leaving temperatures within a -3°C (26.6°F)

/ -4°C (24.8°F) dead band.

The unit was installed in December 2017 and com-

missioned in March 2018. There were no performance,

temperature or pressure-drop related issues, and satis-

factory level control and oil draining/oil drain sump volume.

Issues experienced during commissioning involved

high ammonia levelling on start-up due to elevated glycol

temperatures. This was remedied by programing a pump-

out cycle on unit shut-down and pulsing the ammonia liq-

uid feed on start-up. A bigger shell size for initial surge on

start-up is an alternative but more expensive solution.

This unit was the first Vahterus PSHE Combined inte-

gral to an in-house Tri Tech Refrigeration Australia design

to be purchased, installed and put into service. Since then,

the cooperation between Tri Tech Refrigeration Australia

and Vahterus has continued with the:

– commissioning of two US-built packages with on-

board Vahterus glycol chillers in January 2018

– in-house design and installation of two other green-

field plants using three ammonia/CO2 cascade condens-

ers commissioned in January 2019 and January 2020

– installation and commissioning of five NewTon

packages built by Mayekawa with Vahterus Plate & Shell

technology in July 2019

– in-house design of another ammonia glycol chiller

with an 800kW (227 Ton) capacity due to be built and in-

stalled in Q2 2020 and commissioned in Q3 2020

– selection of additional units for conceptual designs

for potential future projects requiring Combined in ammo-

nia/CO2 cascade, ammonia desuperheating, glycol chilling

and ammonia sub-cooling/economising applications.

36

Panasonic Appliance Refrigeration System (Dalian) Co.,

Ltd is one of the leading refrigeration system and indus-

trial refrigeration turnkey project providers in China. The

company has successfully completed several green cold-

chain projects for Chinese e-commerce market leaders,

many of them based on the natural refrigerant CO2.

Huachen Longdefeng Group has a diversified busi-

ness portfolio, including real estate, financial investment,

asset management, food importing and logistics. The

e-commerce boom in China created strong demand for

the group’s logistics business. In 2017, Huachen group in-

vested in a new energy-efficient logistic centre. Panason-

ic won the refrigeration contract.

The centre has cold stores in two three-storey build-

ings. Each storey has a floor area of 7,500m2. In Complex

No.4, the high temperature zone has three cold rooms

with a design temperature of 0 to 5°C. It can store up to

1,770 tons of goods. The low temperature zone has one

cold room with a design temperature of -23 to -25°C. It

can store up to 16,450 tons of goods. The deep freezing

zone has one cold room with a design temperature of

-55 to -60°C. It can store up to 800 tons of goods. The

buffer zone has one cold room with a design tempera-

ture of -25°C. In Complex No.5, the low temperature zone

consists of 17 rooms with a design temperature of -18 to

-20°C and it can store up to 19,090 tons of goods. Both

buildings have a passage and processing area designed

at 5–10°C.

Panasonic designed R507/CO2 refrigeration systems

for cold rooms -23 to -25°C in Complex No. 4 and cold

rooms -18 to -20°C in Complex No. 5. In these systems,

CO2 operates as brine. Each complex has two indepen-

dent CO2 systems to ensure that the goods stored in

them are safely preserved.

The cascade heat exchanger is a critical piece of

equipment between the two refrigeration systems. The

Panasonic team made a thorough technical evaluation

of different heat exchanger technologies and brands.

Vahterus was chosen to supply the PSHEs for this proj-

ect due to its strong market reputation and the techni-

cal advantage of its PSHEs. The compact size lowers the

system refrigerant charge. High heat transfer efficiency

enables closer temperature approach between R507 and

CO2. High suction pressure helps in reducing system en-

ergy consumption. The fully welded construction of PSHE

also minimises leakage risks and is maintenance free.

The PSHEs were installed in October 2018. Huachen’s

project further proves that Vahterus is the right choice for

demanding CO2 refrigeration systems. This adds another

successful green cold-chain project to Panasonic’s port-

folio. The journey continues!

CO2 Cold Store Operates with Energy Efficiency and Sustainability in Eastern China

Yonghai Yi, Senior Sales Engineer at Vahterus China

Case Stories

Panasonic supplied an energy-efficient refrigeration system

with Vahterus PSHE to Huachen Group’s green cold store.

37No.   1 2020

Since 2010, Vahterus has been providing Plate & Shell

Heat Exchangers for building-heat packages manufac-

tured by Preston Phipps for the Canadian Market.

In the early 2000s, there was a change in the ap-

proach to providing building heat for the institutional

and commercial markets. In the past, contractors put

together packages on site, based on drawings and

specifications provided by the design consultants.

Once these systems were installed, the end-user and

maintenance personnel were faced with many different

systems throughout their facilities. After the warran-

ty period ended, service became difficult because no

The Beauty of Being Compact: Efficient building-heat packages open doors in Canada

Leonardo Berardinelli, Vice-President Production Division at Preston Phipps Inc, Montreal

Case Stories

Vahterus provides Plate & Shell Heat Exchanger design for building-heat packages manufactured by Preston Phipps. The compact

design makes it possible to manufacture skid assemblies that can handle large loads and take up a much smaller footprint.

38No.   1 2020

single- source vendor was responsible for the system,

and facility maintenance staff became increasingly

frustrated by having to deal with multiple vendors for

support.

As the years passed, buildings aged and so too

did the building heating systems. Replacing huge Shell

& Tube heat exchangers without demolishing existing

architecture was challenging. New buildings were de-

signed with smaller mechanical rooms. The old design

model needed to be rethought and a different approach

was required.

Design consultants were now looking for packaged

solutions that were manufactured and designed by a

single-source vendor, who would later be the sole re-

sponsible vendor for maintenance and any possible is-

sues. Faced with this challenge, Preston Phipps decided

to look at building heat differently. The idea of conven-

tional steam-side controlled Shell & Tube heat exchang-

ers needed updating. Although this design worked well,

smaller mechanical rooms and more energy-efficient

design criteria meant that it was time to look for alter-

native solutions.

Since steam was the energy source, the idea of

looking at condensate-controlled, or flooded, heat ex-

changer solutions was the path forward. The design’s

simplicity meant better control, less equipment and a

smaller footprint. In addition, the market was asking for

maximum energy savings, which could be achieved by

the sub-cooling condensate. The last challenge was

getting away from the traditional Shell & Tube heat ex-

changer and finding a different technology that was ef-

ficient and compact.

And so the success story began! Vahterus, pro-

vided us with the Plate & Shell Heat Exchanger design.

Their technology made it possible to manufacture skid

assemblies that can handle large loads and take up a

much smaller footprint in mechanical rooms. Older

buildings could easily be retrofitted by moving these

new packages through narrow hallways and elevators.

Newer buildings could take advantage of the compact

footprint and use the saved space for real estate.

The success of these packages eventually led to

the trade marketing of COMPACKHEAT by Preston

Phipps. Throughout the years, hundreds of these pack-

ages have been sold across the Canadian market. The

move to this design has opened the doors to countless

opportunities. Designs have become standardised and

many facilities are slowly replacing their older systems

and adopting the COMPACKHEAT way of thinking.

Vahterus Plate & Shell Heat Exchanger technology com-

bines the superior heat transfer of the gasketed plate-

type heat exchanger with the Shell & Tube tolerance for

pressure and temperature. These highly innovative de-

sign characteristics in such a compact product, and our

continued partnership with Vahterus, have allowed us to

succeed.

Although Vahterus and Preston Phipps are in differ-

ent countries, they share common values. Delivering a

high-quality product, attention to detail and customer

service are just a few examples of the appreciation and

trust that our companies have for each other. Both or-

ganisations share business models that include re-in-

vestment, growth creation for valued employees and

the willingness to meet objectives and challenges.

The move to a new compact design has opened the doors to

countless opportunities. Throughout the years, hundreds of

rationalised building-heat packages have been sold across the

Canadian market. Designs have become standardised and many

facilities are slowly replacing their older systems. The highly

innovative design characteristics in such a compact product, and our

continued partnership with Vahterus, have allowed us to succeed.

39No.   1 2020

30 years in Heat Transfer

Vahterus’ journey began in 1990. Through extensive R&D work and with 60,000 heat exchangers delivered to customers all over the world, we’re now leaders in the field.

Read more success stories in the next issue where we celebrate our 30th anniversary.

vahterus.com